installation two-stage gas-fired mid-efficiency … · downflow models p*dd / g8d-dn downflow 1 6 0...

CONTENTS

GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . 3

UNIT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

VENTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

DUCTWORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

UPFLOW/HORIZONTAL MODELS . . . . . . . . . . . . . . . . . 10

DOWNFLOW MODEL APPLICATION . . . . . . . . . . . . . . . 12

GAS PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

ELECTRICAL POWER CONNECTION . . . . . . . . . . . . . . 14

ELECTRICAL CONTROL CONNECTIONS . . . . . . . . . . . 14

SAFETY CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

START-UP AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . 16

ACCESSORY CONNECTIONS . . . . . . . . . . . . . . . . . . . . 20

FURNACE ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . 20

FILTER PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . 22

OPERATION AND MAINTENANCE . . . . . . . . . . . . . . . . . 23

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

SEQUENCE OF OPERATION . . . . . . . . . . . . . . . . . . . . . 28

WIRING DIAGRAM - UPFLOW / HORIZONTAL MODELS(P*DU / G8D-UH & L8D-UH). . . . . . . . . . . . . . . . . . . . . . . 29

WIRING DIAGRAM - DOWNFLOW (P*DD & G8D-DN) . 30

INSTALLATIONINSTRUCTION

CAUTION: READ ALL SAFETY GUIDES BEFORE YOUSTART TO INSTALL YOUR FURNACE.

SAVE THIS MANUAL

TWO-STAGE

GAS-FIRED MID-EFFICIENCY FURNACES

TUBULAR HEAT EXCHANGER SERIES

MODELS: P*DU / G8D-UH / L8D-UH (Upflow/Horizontal)

P*DD & G8D-DN (Downflow)

57 - 120 MBH INPUT

035-17429-000 REV B (0801)

035-17429-000 REV A (04/00)

2 Unitary Products Group

IMPROPER INSTALLATION MAY CREATE ACONDITION WHERE THE OPERATION OF THEPRODUCT COULD CAUSE PERSONAL INJURYOR PROPERTY DAMAGE.

IMPROPER INSTALLATION, ADJUSTMENT,ALTERATION, SERVICE OR MAINTENANCECAN CAUSE INJURY OR PROPERTY DAMAGE.REFER TO THIS MANUAL FOR ASSISTANCEOR ADDITIONAL INFORMATION, CONSULT AQUALIFIED INSTALLER, SERVICE AGENCY ORTHE GAS SUPPLIER.

THIS PRODUCT MUST BE INSTALLED INSTRICT COMPLIANCE WITH THE ENCLOSEDINSTALLATION INSTRUCTIONS AND ANYAPPLICABLE LOCAL, STATE, AND NATIONALCODES INCLUDING BUT NOT LIMITED TO,BUILDING, ELECTRICAL AND MECHANICALCODES.

The furnace area must not be used as a broomcloset or for any other storage purposes, as a firehazard bay be created. Never store items such asthe following on, near or in contact with the fur-nace.

1. Spray or aerosol cans, rags, brooms, dust mops,vacuum cleaners or other cleaning tools.

2. Soap powders, bleaches, waxes or other cleaningcompounds; plastic items or containers; gasoline,kerosene, cigarette lighter fluid, dry cleaning fluidsor other volatile fluid.

3. Paint thinners and other painting compounds.

4. Paper bags, boxes or other paper products

Never operate the furnace with the blower doorremoved. To do so could result in serious personalinjury and/or equipment damage.

WARNING

CAUTION

WARNING

GENERAL INFORMATION

DESCRIPTION

This Category I furnace is designed for installation in a resi-dential or commercial application. A Category I furnace has afan assisted combustion system equipped with an integralmechanical means to draw products of combustion throughthe combustion chamber and heat exchanger. It may beinstalled in a basement, garage, equipment room, alcove,attic or any other indoor location where all required clear-ances to combustibles and other restrictions are met. It isdesigned for natural gas-fired operation, for use in standardand LoNox applications.

High altitude and propane (LP) changes or conversionsrequired in order for the appliance to satisfactorily meet theapplication must be made by an authorized contractor: inCanada, a certified conversion station or other qualifiedagency, using factory specified and/or approved parts.

Upflow/horizontal furnaces and downflow furnaces may beused only as Category I units.

The furnace must be installed so that all electrical compo-nents are protected from water.

INSPECTION

As soon as a unit is received, it should be inspected for possi-ble damage during transit. If any damage is evident, theextent of the damage should be noted on the carrier's freightbill.

A separate request for inspection by the carrier's agentshould be made in writing. Also, before installation, the unitshould be checked for screws or bolts which may have loos-ened in transit.

LoNox furnaces requiring propane (LP) gas musthave the LoNox screens removed prior toinstallation and operation. See propane instruction035-14488-000 for instructions on proper removalof the Nox screens.

CAUTION

035-17429-000 REV B (0801)

Unitary Products Group 3

NOTES, CAUTIONS & WARNINGS

The installer should pay particular attention to the words:NOTE, CAUTION and WARNING. NOTES are intended toclarify or make the installation easier. CAUTIONS are givento prevent equipment damage. WARNINGS are given to alertthe installer that personal injury and/or equipment or propertydamage may occur if installation procedures are not handledproperly.

Each furnace in this series is a Category I furnace, suitablefor common venting with other gas-fired appliances asallowed by the National Fuel Gas Code, NFPA 54/ANSIZ223.1-latest edition.

LIMITATIONS AND LOCATION

This furnace should be installed in accordance with allnational/local building/safety codes and requirements, or inthe absence of local codes, with the National Fuel Gas Code,ANSI Z223.1 - (latest edition) or, in Canada, CAN/CGAB149.1 or.2 - (latest edition), and other applicable codes.

Use only the type of gas approved for this furnace; refer tothe furnace rating plate.

For installations above 2,000 feet, reduce input 4% for each1,000 feet above sea level. Canadian installations must bederated 10% for elevations from 2,000 ft. to 4,500 ft. SeeForm 035-14461-000 for information to properly deratefurnace.

For installations between 2,000 and 4,500 feet, it is notrequired that the pressure switch be changed. For altitudesabove 4,500 feet, the appropriate high altitude kit must beused.

Furnace shall not be connected to a chimney flue serving aseparate appliance designed to burn solid fuel.

Check the rating plate and power supply to be sure that elec-trical characteristics match. All models use nominal 115 vac,1 phase, 60 Hz. power supply.

A furnace installed in a residential garage must be located sothat all burners and burner ignition devices are located noless than 18" above the garage floor, and located or pro-tected to prevent damage by vehicles.

The size of the unit should be based on an acceptable heatloss calculation for the structure. ACCA, Manual J or otherapproved methods may be used.

The furnace should be located using these guidelines:

1. Where a minimum amount of vent piping and elbows willbe required.

2. As centralized with the air distribution as possible.

3. Where adequate combustion air will be available.

4. In an area where ventilation facilities provide for safe lim-its of ambient temperature under normal operating condi-tions.

5. Where it will not interfere with proper air circulation in theconfined space.

6. Where the vent will not be blocked or restricted.

7. Where sufficient space is provided to allow proper ser-vice access. Minimum recommended service clearancesare as follows:

• Twenty-four (24) inches between the front of the fur-nace and an adjacent wall or another appliance,when access is required for servicing and cleaning.

• Eighteen (18) inches at the side where access isrequired for passage to the front when servicing orfor inspection or replacement of flue/vent connec-tions.

8. Where it will not interfere with the cleaning, servicing orremoval of other appliances.

9. Where the following minimum clearances (in inches) tocombustibles can be maintained. Please see Table 1.

This appliance is not to be used for temporary heatingof buildings or structures under construction.

Do not install this furnace in a corrosive orcontaminated atmosphere.

Do not install this furnace in a mobile home orrecreational vehicle.

Furnaces shall not be installed directly on carpeting,tile or other combustible material other than woodflooring. When installing a counterflow furnace on awood floor, a combustible floor base must be used.

Only use natural gas in furnaces designed fornatural gas. Only use propane (LP) gas for fur-naces that have been properly converted to usepropane (LP) gas. Do not use this furnace withbutane. Using wrong gas could create a hazard,resulting in damage, injury or death.

CAUTION

WARNING

035-17429-000 REV B (0801)


TABLE 1: UNIT CLEARANCES TO COMBUSTIBLES (ALL DIMENSIONS IN INCHES)(All surfaces identified with the unit in an upflow configuration)

APPLICATION TOP FRONT REARLEFTSIDE

RIGHTSIDE

FLUEFLOOR/BOTTOM

CLOSET ALCOVE ATTICLINE

CONTACT

UPFLOW / HORIZONTAL MODELS P*DU/ G8D-UH / L8D-UH

UPFLOW 1 6 0 0 3* 6 COMBUSTIBLE YES YES YES NO

UPFLOW B-VENT 1 3 0 0 0 1 COMBUSTIBLE YES YES YES NO

HORIZONTAL 3† 6 0 1 0 6 COMBUSTIBLE NO YES YES YES‡

HORIZONTAL B-VENT 0 3 0 1 0 1 COMBUSTIBLE NO YES YES YES‡

DOWNFLOW MODELS P*DD / G8D-DN

DOWNFLOW 1 6 0 0 3 6 1** YES YES YES NO

DOWNFLOW B-VENT 1 3 0 0 0 1 1** YES YES YES NO

*. 14-1/2” cabinet models only - all other units “0” clearance.†. 14-1/2” cabinet left airflow applications only - all other units and right hand airflow applications “0” clearance.‡. Line contact only permitted between lines formed by the intersection of the rear panel and side panel (top in horizontal position) of

the furnace jacket and building joists, studs or framing.**. Special floor base or air conditioning coil required for use on combustible floor.

035-17429-000 REV B (0801)


UNIT INSTALLATION

COMBUSTION AIR

All installations must comply with Section 5.3, Air for Com-bustion and Ventilation of the National Fuel Gas Code, ANSIZ223.1 or Sections 7.2, 7.3 or 7.4 of CAN/CGA B149.1 or.2Installation Code - latest editions.

An unconfined space is not less than 50 cubic feet per 1000Btu/hr input rating for all appliances installed in that area.

Rooms communicating directly with the space containing theappliances are considered part of the unconfined space, ifopenings are not furnished with doors.

A confined space is an area with less than 50 cubic feet per1000 Btu/hr input rating for all appliances installed in thatarea.

The following must be considered to obtain proper air forcombustion and ventilation in confined spaces.

Air Source from Inside the Building -

Two permanent openings, one within 12 inches of the top ofthe confined space and one within 12 inches of the bottom,shall each have a free area of not less than one square inchper 1,000 Btuh of total input rating of all appliances located inthe space. The openings shall communicate freely with inte-rior areas having adequate infiltration from the outside.

NOTE: At least 100 square inches free area shall be used foreach opening.

Air Source from Outdoors -

1. Two permanent openings, one within 12 inches of thetop of the confined space and one within 12 inches of thebottom, shall communicate directly, or by means ofducts, with the outdoors or to such crawl or attic spacesthat freely communicate with the outdoors.

a. Vertical Ducts - Each opening must have a freearea of not less than one square inch per 4,000 Btuhof total input of all appliances located in the space.

EXAMPLE:

b. Horizontal Ducts - Each opening must have a freearea of not less than one square inch per 2,000 Btuhof total input of all appliances located in the space.

NOTE: Ducts must have the same cross-sectional area asthe free area in the opening to which they are connected. Theminimum dimension of rectangular ducts shall be threeinches.

2. One permanent opening, commencing within 12 inchesof the top of the enclosure shall be permitted where theequipment has clearances of at least 1 inch from thesides and back and 6 inches from the front of the appli-ance. The opening shall communicate through a verticalor horizontal duct to the outdoors, or spaces (crawl orattic) that freely communicate with the outdoors and shallhave a minimum free area of:

a. 1 sq. in. per 3000 Btu per hr of the total input ratingof all equipment located in the enclosure.

b. Not less than the sum of the areas of all vent con-nectors in the confined space.

3. Louvers, Grilles and Screens

a. In calculating free area, consideration must be givento the blocking effects of louvers, grilles andscreens.

b. If the free area of a specific louver or grill is notknown, refer to Table 2 to estimate free area.

.

NOTE: If mechanically operated louvers are used, a meansto prevent main burner ignition and operation must be pro-vided should louvers close during startup or operation.

Special Combustion and Ventilation Considerations

Operation of a mechanical exhaust, such as an exhaust fan,kitchen ventilation system, clothes dryer or fireplace may cre-ate conditions requiring special attention to avoid unsatisfac-tory operation of gas appliances.

Specially Engineered Installations

The above requirements shall be permitted to be waivedwhere special engineering, approved by the authority havingjurisdiction, provides an adequate supply of air for combus-tion, ventilation and dilution of flue gases.

Total Input of All Appliances= Square Inches Free Area

4000

TABLE 2: ESTIMATED FREE AREA

Wood or MetalLouvers or Grilles

Wood 20-25%*

Metal 60-70%*

*. Do not use less than 1/4 in. mesh

Screens†

†. Free area or louvers an grilles varies widely; installershould follow louver or grille manufacturer’s instruc-tions.

1/4 in. mesh or larger 100%

035-17429-000 REV B (0801)


Combustion Air Quality

The recommended source of combustion air is to use the out-door air supply. Excessive exposure to contaminated com-bustion air will result in safety and performance relatedproblems. However, the use of indoor air in most applicationsis acceptable, except as follows:

1. If the furnace is installed in a confined space it is recom-mended that the necessary combustion air come fromthe outdoors by way of attic, crawl space, air duct ordirect opening.

2. If outdoor combustion air is used, there must be no expo-sure to the installations or substances listed in # 3 below.

3. The following types of installations may require OUT-DOOR AIR for combustion, due to chemical exposure.

a. Commercial buildingsb. Buildings with indoor poolsc. Furnaces installed in laundry roomsd. Furnaces installed in hobby or craft roomse. Furnaces installed near chemical storage areas

Exposure to the following substances in the combustion airsupply may also require OUTDOOR AIR for combustion.

f. Permanent wave solutionsg. Chlorinated waxes and cleanersh. Chlorine based swimming pool chemicalsi. Water softening chemicalsj. De-icing salts or chemicalsk. Carbon tetrachloridel. Halogen type refrigerantsm. Cleaning solvents (such as perchloroethylene)n. Printing inks, paint removers, varnishes, etc.o. Hydrochloric acidsp. Cements and gluesq. Antistatic fabric softeners for clothes dryersr. Masonry acid washing chemicals

VENTING

CATEGORY I VERTICAL VENTING

Category I venting consists of vertically venting one or moreappliances in B-vent or masonry chimney (as allowed), usingsingle wall metal pipe or B-vent connectors. Type B-vent sys-tem extends in a general vertical direction and does not con-tain offsets exceeding 45 degrees, except that a vent systemhaving not more than one 60-degree offset is permitted.

NOTE: This appliance may be common vented with anothergas appliance as allowed by the following codes and stan-dards.

The furnace rating plate lists the maximum vent gas tempera-ture. This temperature must be used to select appropriateventing materials and clearances. A typical example is shownbelow.

CATEGORY 1 - 450 F. MAX. VENT TEMP.

All installations must be vented in accordance with theNational Fuel Gas Code, NFPA 54/ANSI Z223.1 - latest edi-tion. For reference, the National Fuel Gas Code Handbook,available from NFPA (item JP-54HB96) is recommended.The appliance must also be vented in compliance with alllocal utility and code requirements. In Canada, the furnacemust be vented in accordance with the National Standard ofCanada, CAN/CGA-B149.1 and.2 - latest editions.

VENTING INTO AN EXISTING CHIMNEY

Whenever possible, B-1 metal pipe should be used for vent-ing. Where use of an existing chimney is unavoidable, the fol-lowing rules must be followed:

1. The masonry chimney must be built and installed inaccordance with nationally recognized building codes orstandards and must be lined with approved fire clay tileflue liners or other approved liner material that will resistcorrosion, softening, or cracking from flue gases. THISFURNACE IS NOT TO BE VENTED INTO AN UNLINEDMASONRY CHIMNEY.

2. This furnace must be vented into a fire clay tile linedmasonry chimney only if a source of of dilution air is pro-vided, such as by common venting with a draft hoodequipped water heater. If no source of dilution air is avail-able, Type B vent must be used, or masonry chimneyvent kit 1CK0603 or 1CK0604 must be used. See form035-17452-000 to properly apply these masonry chim-ney kits.

3. The chimney must extend at least three feet above thehighest point where it passes through a roof of a buildingand at least two feet higher than any portion of the build-ing with a horizontal distance of ten feet.

4. The chimney must extend at least five feet above thehighest equipment draft hood or flue collar.

It is the responsibility of the installer to verifyproper vent system operation.

WARNING

A furnace shall not be connected to a chimney flueserving a separate appliance designed to burnsolid fuel.

CAUTION

035-17429-000 REV B (0801)


All dimensions are in inches and are approximate

FIGURE 1: 2-STAGE UPFLOW/HORIZONTAL FURNACE DIMENSIONS

TABLE 3: 2-STAGE UPFLOW/HORIZONTAL RATINGS & PHYSICAL/ELECTRICAL DATA

MODELS P*DU/ G8D-UH /L8D-UH

CABINET

WIDTH (IN.) AFUE*LOW FIRE

TEMP RISE

°F

HIGH

FIRE

TEMP

RISE °F

MAX.OUTLET

AIR TEMP

°F

BLOWERTOTAL

UNIT

AMPS

MAX.OVER-

CURRENT

PROTECT†

MIN WIRE

SIZE

(AWG) @75 FT.

ONE WAY†

OPER

WGT.(LBS)

INPUT

MBH H/LOUTPUT

MBH H/LNOM.CFM HP AMPS SIZE (IN)

57/42 46/34 1200 “A” 14-1/2 80.0 25 - 55 35 - 65 165 1/3 6.2 10 x 7 9.0 20 14 105

80/59 64/48 1200 “A” 14-1/2 80.0 30 - 60 40 - 70 175 1/3 6.2 10 x 7 9.0 20 14 117

80/59 64/48 1600 “B” 17-1/2 80.0 25 - 55 25 - 55 160 3/4 11.5 11 x 8 12.0 20 14 126

100/65 80/53 1200 “B” 17-1/2 80.0 25 - 55 40 - 70 170 1/2 7.0 10 x 8 12.0 20 14 128

100/65 80/53 2000 “C” 21 80.0 25 - 55 30 - 60 160 1 12.2 11 x 10 14.0 20 12 145

120/78 96/64 1600 “C” 21 80.0 25 - 55 45 - 75 180 1/2 10.4 10 x 10 12.0 20 14 145

120/78 96/64 2000 “C” 21 80.0 25 - 55 35 - 65 170 1 12.2 11 x 10 14.0 20 12 147

*. AFUE numbers are determined in accordance with DOE test procedures.†. Wire size and overcurrent protection must comply with the National Electrical Code (NFPA-70-latest edition).• For altitudes above 2,000 ft., reduce capacity 4% for each 1,000 ft. above sea level. Refer to Form 035-14461-000.• Wire size based on copper conductors, 60° C, 3% voltage drop.• Continuous return air temperature must not be below 55° F.

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3/4

F R O N TF R O N T LEFT S IDELEFT S IDE RIGHT S IDERIGHT S IDE

OPTIONAL SIDERETURN CUT-OUT(EITHER SIDE)

14

GAS INLET1-1/4" X 2-1/2" 2

2-1/4

1-1/8

D

(Vent Connection)

14-3/45-3/8

8-3/4

2-1/2

16

13-3/4POWER WIRING

ACCESS WIRING7/8" K.O.

32-1/2

T'STAT WIRING7/8" K.O.

7/8" HOLE

B

40

A 28-1/2

20

23-1/2

Upflow/HorizontalModels P*DU /

G8D-UH / L8D-UH*A B C D E F

57 / 46 / 1200 / “A” 14-1/2 13-1/4 10-1/8 4 10-1/8 3-3/4

80 / 64 / 1200 / “A” 14-1/2 13-1/4 10-1/8 4 10-1/8 3-3/4

80 / 64 / 1600 / “B” 17-1/2 16-1/4 13-1/8 4 11-5/8 3-3/4

100 / 80 / 1200 / “B” 17-1/2 16-1/4 13-1/8 4 11-5/8 3-3/4

100 / 80 2000 / “C” 21 19-3/4 16-5/8 4 13-3/8 3-3/4

120 / 96 / 1600 / “C” 21 19-3/4 16-5/8 4 13-3/8 3-3/4

120 / 96 / 2000 / “C” 21 19-3/4 16-5/8 4 13-3/8 3-3/4

*. Input / Output / CFM / Cabinet

035-17429-000 REV B (0801)


All dimensions are in inches and are approximate.

FIGURE 2 : 2-STAGE DOWNFLOW FURNACE DIMENSIONS

TABLE 4: 2-STAGE RATINGS & PHYSICAL/ELECTRICAL DATA

MODELS P*DD & G8D-DN

CABINET

WIDTH (IN.) AFUE*

LOW

FIRE

TEMP

RISE °F

HIGH

FIRE

TEMP

RISE °F

MAX.OUTLET

AIR TEMP

°F

BLOWERTOTAL

UNIT

AMPS

MAX. OVER-CURRENT

PROTECT†

MIN WIRE

SIZE (AWG)@ 75 FT.

ONE WAY†

OPER

WGT.(LBS)

INPUT

MBH

H/L

OUTPUT

MBH H/LNOM.CFM HP AMPS SIZE (IN)

57/42 46/34 1200 “A” 14-1/2” 80.0 20 - 50 30 - 60 160 1/3 6.2 10 x 8 9.0 20 14 110

80/59 64/48 1200 “A” 14-1/2” 80.0 25 - 55 30 - 60 160 1/3 6.2 10 x 8 9.0 20 14 120

80/59 64/48 1600 “B” 17-1/2” 80.0 20 - 50 25 - 55 160 3/4 11.0 11 x 10 12.0 20 14 130

100/65 80/52 1200 “B” 17-1/2” 80.0 25 - 55 40 - 70 170 1/2 7.0 10 x 8 12.0 20 14 125

120/78 96/64 2000 “C” 21” 80.0 25 - 55 30 - 60 160 1 12.2 11 x 10 14.0 20 12 150

*. AFUE numbers are determined in accordance with DOE test procedures.†. Wire size and overcurrent protection must comply with the National Electrical Code (NFPA-70-latest edition).• For altitudes above 2,000 ft., reduce capacity 4% for each 1,000 ft. above sea level. Refer to Form 035-14461-000.• Wire size based on copper conductors, 60° C, 3% voltage drop.• Continuous return air temperature must not be below 55° F.

3/4

FRONT LEFT SIDE RIGHT SIDE

G A S IN L E T 1 - 1 /4 " X 2 - 1 /2 "

D

( V e n t C o n n e c ti o n )

5-3/42-1/2

A L T . G A S IN L E T 1 - 1 /4 " X 2 - 1 /2 "

T ' S T A T W IR IN G 7 /8 " K .O .

31-1/8

28-1/2

20B

40

A

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Downflow Models

P*DD & G8D-DN*

*. Input / Output / CFM / Cabinet

A B C D E F

57 / 46 / 1200 / “A” 14-1/2 13-1/4 12-1/4 4 10-1/8 3-3/4

80 / 64 / 1200 / “A” 14-1/2 13-1/4 12-1/4 4 10-1/8 3-3/4

80 / 64 / 1600 / “B” 17-1/2 16-1/4 15-1/4 4 11-5/8 3-3/4

100 / 80 / 1200 / “B” 17-1/2 16-1/4 15-1/4 4 11-5/8 3-3/4

120 / 80 / 2000 / “C” 21 19-3/4 18-3/4 4 13-3/8 3-3/4

035-17429-000 REV B (0801)


VENT SAFETY CHECK PROCEDURE

The following steps shall be followed with each applianceconnected to the venting system placed in operation, whileany other appliances connected to the common venting sys-tem are not in operation.

1. Seal any unused openings in the common venting sys-tem.

2. Inspect venting system for proper size and horizontalpitch, as required in the National Fuel Gas Code ANSIZ223.1 or the CAN/CGA B149 Installation Codes andthese instructions. Determine that there is no blockageor restriction, leakage, corrosion or other deficiencieswhich could cause an unsafe condition.

3. Insofar as is practical, close all building doors and win-dows and all doors between the space in which the appli-ance(s) connected to the venting system are located andother spaces of the building. Turn on clothes dryers andany other appliances not connected to the common vent-ing system. Turn on any clothes dryers and any appli-ance not connected to the venting system.

Turn on any exhaust fans, such as range hoods andbathroom exhausts so they will operate at maximumspeed. Do not operate a summer exhaust fan. Close fire-place dampers.

4. Follow the lighting instructions. Place the appliancebeing operated in operation. Adjust thermostat so appli-ance will operate continuously.

5. Test for draft hood equipped appliance spillage at thedraft hood relief opening after 5 minutes of main burneroperation. Use the flame of a match or candle.

6. After it has been determined that each appliance con-nected to the venting system properly vents when testedas outlined above, return doors, windows, exhaust fans,fireplace dampers and any other gas-burning applianceto their previous conditions of use.

7. If improper venting is observed during any of the abovetests, the venting system must be corrected.

8. Any corrections or resizing of the common venting sys-tem must be in accordance with the National Fuel GasCode, ANSI Z223.1 or Section 7, Venting Systems andAir Supply for Appliances, CAN/CGA B149.1 or.2 Instal-lation Code - latest editions. If the common vent systemmust be resized, it should be resized to approach theminimum size as determined using the appropriatetables in Appendix G of the above codes or the ventingtables supplied with the furnace.

DUCTWORK

The duct system's design and installation must:

1. Handle an air volume appropriate for the served spaceand within the operating parameters of the furnace spec-ifications.

2. Be installed in accordance with standards of NFPA(National Fire Protection Association) as outlined inNFPA pamphlets 90A and 90B - (latest editions).

3. Create a closed duct system. The supply system mustbe connected to the furnace outlet and the return ductsystem must be connected to the furnace inlet. Both sup-ply and return duct systems must terminate outside thespace containing the furnace.

4. Generally complete a path for heated or cooled air to cir-culate through the air conditioning and heating equip-ment and to and from the conditioned space.

When the furnace is used in conjunction with a cooling coil,the furnace must be installed parallel with, or in the supply airside of the furnace.

When a parallel flow arrangement is used, the dampers orother means used to control air flow must be adequate to pre-vent chilled air from entering the furnace, and if manuallyoperated, must be equipped with means to prevent operatingof either unit unless the damper is in the full heat or cool posi-tion.

If this furnace is replacing a common-vented fur-nace, it may be necessary to resize the existingvent line and chimney to prevent oversizing prob-lems for the new combination of units. Refer to theNational Fuel Gas Code, ANSI Z223.1 or CAN/CGA B149.1 or.2 Installation Code - latest edi-tions.

CAUTION

The cooling coil must be installed in the supply airduct downstream of the furnace.

CAUTION

035-17429-000 REV B (0801)


UPFLOW/HORIZONTAL MODELS

UPFLOW APPLICATION

Supply Plenum Connection

Attach the supply plenum to the fur-nace outlet duct connection flanges.This is typically through the use of Scleat material when a metal plenum isused. The use of an approved flexibleduct connector is recommended on allinstallations. This connection should besealed to prevent air leakage.

If a matching cooling coil is used, itmay be placed directly on the furnaceoutlet and sealed to prevent leakage.Follow the coil instructions for installingthe supply plenum.

On all installations without a coil, a removable access panelis recommended in the outlet duct such that smoke orreflected light would be observable inside the casing to indi-cate the presence of leaks in the heat exchanger. Thisaccess cover shall be attached in such a manner as to pre-vent leaks.

Return Duct Connection

Return air may enter the furnace through the side(s) or bot-tom depending on the type of application. Return air maynot be connected into the rear panel of the unit. Refer tothe “Filters Installation” section for the type of applicationdesired for specific installation details.

NOTE: In order to achieve the airflow indicated in the table, itis recommended for those applications over 1800 CFM usereturn air from two sides, one side and the bottom, or bottomonly. For bottom only application, see data and notes onblower performance data tables in this manual.

FILTERS INSTALLATION

(UPFLOW/HORIZONTAL)

All applications require the use of a filter. A high velocity filterand retainer are provided for field installation.

Internal Installation

1. Select desired filter position (left/right side, and/or bot-tom). Remove the corresponding cabinet cut-outs perinstructions provided.

2. Install snap-in retainer clips into the corresponding slotsfrom the outside rear of the cabinet. Refer to Figure 3.To prevent cabinet air leaks, install snap-in plugs (pro-vided) into the unused slots at the outside rear of thecabinet.

3. Install the wire retainer inside the cabinet. Insert theopen ends of the wire retainer into the clip loops at therear of the blower compartment. The retainer wire shouldpivot freely like a hinge, on the clips at the rear of thecabinet. Refer to Figure 4.

4. Install the filter(s) provided. Cut filter if necessary tomatch air opening in cabinet. Filter should extendbeyond opening edge as much as possible to prevent airfrom bypassing the filter. DO NOT remove stiffening rodsfrom inside the filter. Shorten the rods, if necessary, tomatch final filter size.

5. Position the filter between the wire retainer and the cabi-net wall (or floor) so it completely covers the cabinet airopening and secure the filter in place at the front of thecabinet by fastening the closed (looped) end of theretainer wire under the flanged edge of the cabinet.When properly installed the filter should fit flush with allfour sides of the cabinet wall.

FIGURE 3 : FURNACE FILTER SLOT LOCATIONS

FIGURE 4 : SIDE FILTER RETAINER PLACEMENT

F U R N A C E ( R E A R C A B IN E T )

R IG H T S ID E S L O T S

L E F T S ID E S L O T S

B O T T O M S L O T S

C A B IN E T S L O T

F IL T E R S U P P O R T C L IP S ( P R O V ID E D )

P L U G U N U S E D C A B IN E T S L O T SW IT H P L U G S ( P R O V ID E D )

RIGHT SIDEINSTALLATIONSHOW N

CLIPSFILTER

(PROVIDED

POSITION WIRE RETAINER UNDER FLANGE

FURNACEFRONT

(IF PROVIDED)

FILTER(IF PROVIDED)

035-17429-000 REV B (0801)


NOTE: Air velocity through throw-away type filters may notexceed 300 feet per minute. All velocities over this require theuse of high velocity filters.

Side Return - External Filter

A 1SR0302BK External Filter rack accessory is available formounting filters external to the cabinet.

Locate and knock out the square corner locators. These indi-cate the size of the cutout to be made in the furnace sidepanel. Refer to Figure 5.

Install the side filter rack following the instructions providedwith that accessory. If a filter(s) is provided at another loca-tion in the return air system, the ductwork may be directlyattached to the furnace side panel.

NOTE: Some accessories such as electronic air cleaners andpleated media may require a larger side opening.

The return duct may be attached to the furnace by S-cleat,bend tabs or other approved methods. Be sure to seal theduct to the furnace to prevent air leakage.

Where the return duct system is not complete, the return con-nection must run full size to a location outside the utility room,basement or space where the furnace is installed. For furtherdetails, consult Section 5.3 (Air for Combustion and Ventila-tion) of the National Fuel Gas Code, ANSI Z223.1, or CAN/CGA B149.1 or.2, Installation Code - latest editions.

Bottom Return

Bottom return applications normally pull return air through abase platform or return air plenum. Be sure the return plat-form structure is suitable to support the weight of the furnace.Refer to Figure 3 on page 10 for unit dimensions and Table 3on page 7 for unit weights. Be sure to seal the furnace to ple-num connection to prevent air leakage.

The bottom panel is equipped with a perforated opening foreasy removal. Tabs must be cut with sheet metal snips toallow removing knock-out. Scribe marks are included forforming flanges for attachment of the return air ductwork.

NOTE: If an external mounted filter rack is being used, seethe instructions provided with that accessory for proper holecut size.

Upflow attic installations must meet all minimum clearancesto combustibles and have floor support with required serviceaccessibility.

HORIZONTAL APPLICATION

Upflow furnaces may be installed horizontally with the supplyairflow toward the left or right by laying the unit on the left orright side panel.

After determining the best orientation, lay the unit on top ofthe shipping carton to protect the finish.

The appropriate electrical knock-outs for power wiring, con-trol wiring and gas piping should be removed at this time.

For horizontal application, return air may enter through thebottom, left side or right side panel or any combination ofthese openings. Return air may not be connected into therear panel of the unit.

To convert the upflow model furnace to open bottom, See“ Bottom Return” section of this manual.

FIGURE 5 : SIDE RETURN CUTOUT MARKINGS

All installations must have a filter installed.

FRONT OFFURNACE

CORNERMARKINGS

CAUTION Do not install the unit on the rear panel.

WARNING

035-17429-000 REV B (0801)


ATTIC INSTALLATION

This appliance is design certified for line contact for furnacesinstalled horizontally. The intersection of the furnace top andsides form a line. This line may be in contact with combustiblematerial.

Secure a platform constructed of plywood or other buildingmaterial to the floor joists. Sheet metal, 12" in front of the fur-nace combustion air openings is recommended. Refer to Fig-ure 6.

NOTE : See crawl space installation for suspending the fur-nace in attic installations.

CRAWL SPACE INSTALLATION

The furnace can be hung from floor hoists or installed on suit-able blocks or pad. Blocks or pad installations shall provideadequate height to ensure the unit will not be subject to waterdamage.

When suspending the furnace from rafters or floor joists usingrod, pipe or straps, refer to Table 3 on page 7 for furnaceweights to determine suitable means of suspension.

Angle supports should be placed at the supply air end andnear the blower deck. Refer to Figure 7. Do not support atreturn air end of unit.

Units may also be suspended by using straps or other mate-rial at the same location. All four suspension points must belevel to ensure quiet furnace operation.

DOWNFLOW MODEL APPLICATION

DOWNFLOW FILTERS

A top return filter rack is supplied withthe furnace. Two 14" x 20" permanentwashable filters are supplied with eachunit.

Downflow furnaces typically areinstalled with the filters located abovethe furnace, extending into the returnair duct.

Any branch duct must attach to the ver-tical ductwork above the filter height(FH) in Figure 8. For dimensions Referto Figure 8 on page 13 for properinstallation.

The filter rack (provided) should be secured to the center ofthe front and rear flanges at the furnace top. Drill a holethrough the front and rear duct flange into the filter rack andsecure it with a sheet metal screw.

Note: If placing the filters near the furnace inlet, it is recom-mended that a filter access door be placed in the return airduct for ease of filter removal and cleaning.

Refer to the unit rating plate for furnace model then see thedimensions page of this instruction for return air plenum

FIGURE 6 : TYPICAL ATTIC INSTALLATION

When a furnace is installed in an attic or otherinsulated space, keep all insulating materials atleast 12" away from furnace and burner combus-tion air openings.

VENT (MAINTAINREQUIRED CLEARANCESTO COMBUSTIBLES)

GAS PIPING

SEDIMENT TRAP

12"30" MINWORK AREA

SHEET METALIN FRONT OF FURNACECOMBUSTIONAIR OPENINGS ISRECOMMENDED

RETURN AIR

SUPPLY AIR

LINE CONTACT ONLY PERMISSIBLEBETWEEN LINES FORMED BY THEINTERSECTION OF FURNACE TOPAND TWO SIDES AND BUILDINGJOISTS, STUDS OR FRAMING

CAUTION

FIGURE 7 : TYPICAL FURNACE INSTALLATIONUSING SUSPENSION MATERIALS

S U P P O R T

R O D

A N G L E IR O N

B R A C K E T

6 " M IN B E T W E E N

R O D & F U R N A C E

1 " M A X B E T W E E N

R O D & F U R N A C E 1 " M A X B E T W E E N

R O D & F U R N A C E

035-17429-000 REV B (0801)


dimensions. Install the plenum following instructions underDuctwork in this instruction.

SUPPLY AIR DUCTS

Installations on combustible material or floors must use acombustible floor base (refer to Figure 9) (1CB0314, 17, 21& 24) as specified on the rating plate or a matching coolingcoil. Follow the instructions supplied with the combustiblefloor base accessory for proper installation.

This base can be replaced with a matching cooling coil, prop-erly sealed to prevent leaks. Follow the cooling coil instruc-tions 23 for installing the plenum.

GAS PIPING

NOTE: An accessible manual shutoff valve must be installedupstream of the furnace gas controls and within 6 feet of thefurnace.

The furnace and its individual shutoff valve must be disconnc-ted from the gas supply piping system during any pressuretesting of that system at test pressures in excess of 1/2 psig(3.48 kPa).

The furnace must be isolated from the gas supply piping sys-tem by closing its individual external manual shutoff valveduring any pressure testing of the gas supply piping systemat test pressures equal to or less than 1/2 psig (3.48 kPa).

Gas piping may be connected from either side of the furnace.Sizing and installation of the supply gas line should complywith the local utility requirements.

The gas supply should be a separate line, installed in accor-dance with the National Fuel Gas Code, ANSI Z223.1, orCAN/CGA B149.1 or.2 Installation Codes - (latest editions).

Some utility companies, or local codes, require pipe sizeslarger than the minimum sizes listed. Using the properly sizedwrought iron, approved flexible or steel pipe, make gas con-nections to the unit. Installation of a drop leg and groundunion is required. Refer to Figure 10.

FIGURE 8 : DOWNFLOW FILTERS

FIGURE 9 : COMBUSTIBLE FLOOR BASEACCESSORY

N O T E : F I L T E R A C C E S S T H R U D U C T -

W O R K M U S T B E P R O V I D E D F O R

R E M O V A L A N D C L E A N I N G

B R A N C H

D U C T S

C R O S S S E C T I O N A - A

( W I T H P L E N U M A N D F I L T E R S )

D U C T W O R K

F I L T E R S

F I L T E R

R A C K F H

R A C K A N D F I L T E R S S E C U R E D

I N S I D E B L O W E R S E C T I O N

F O R S H I P M E N T

F I L T E R R A C K

( F A C T O R Y S U P P L I E D )

C A S I N G S I Z E D I M E N S I O N F H

1 4 - 1 / 2 " 1 3 - 1 / 4 "

1 7 - 1 / 2 " 1 2 - 1 / 2 "

2 1 " 1 1 - 1 / 2 "

2 4 - 1 / 2 " 9 - 3 / 4 "

A

A

+��&$,��

$-%&��

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$��%�,�//

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An overpressure protection device, such as apressure regulator, which conforms to the NationalFuel Gas Code, ANSI Z223.1 (U.S.) or CAN-B149.1 or.2 (Canada) and acts to limit the down-stream pressure to value that does not exceed 0.5PSI (14" w.c.), must be installed in the gas pipingsystem upstream of the furnace. Failure to do somay result in a fire or explosion or cause damageto the furnace or some of its components.

Never apply a pipe wrench to the body of the com-bination automatic gas valve. A wrench must beplaced on the projection or wrench boss of thevalve when installing piping to it.

WARNING

CAUTION

035-17429-000 REV B (0801)


ELECTRICAL POWER CONNECTION

Field wiring to the unit must conform to and be grounded inaccordance with the provisions of the National ElectricalCode ANSI/NFPA No. 70 - latest edition, Canadian ElectricCode C22.1 Part 1 - (latest edition) and/or local codes. Elec-trical wires which are field installed shall conform with thetemperature limitation for 63°F/35°C rise wire when installedin accordance with instructions. Specific electrical data isgiven on the furnace rating plate.

Provide a power supply separate from all other circuits. Installovercurrent protection and disconnect switch per local/national electrical codes. The switch should be reasonablyclose to the unit for convenience in servicing. With the dis-connect switch in the OFF position, check all wiring againstthe unit wiring label. Also, see the wiring diagram in thisinstruction.

.

Connect the power supply as shown on the unit wiring labelon the inside of the blower compartment door and Figures 11& 12. The black furnace lead must be connected to the L1(hot) wire from the power supply.

The white furnace lead must be connected to neutral. Also,the green equipment ground wire must be connected to thepower supply ground.

Remove the screws retaining the wiring box cover. Route thepower wiring through the unit side panel with a conduit con-nector or other proper connection. Make wiring connectionsas shown in Figure 11 or 12. Replace the wiring box coverand screws.

An alternate wiring method is to use a field provided 2 x 4 boxand cover on the outside of the furnace. Route the furnaceleads into the box using a protective bushing where the wirespass through the furnace panel.

NOTE : The power connection leads and wiring box onupflow units may be relocated to the left side of the furnace.Remove the screws and cut wire tie holding excess wiring.Reposition on the left side of the furnace and fasten usingholes provided.

FIGURE 10 : GAS PIPING

Compounds used on threaded joints of gas pipingmust be resistant to the action of liquefied petro-leum gases.

1/8” NPT plug is included in the inlet side of thegas valve for measuring incoming gas pressure.

After all gas piping connections are completed,leak test all joints, fittings and furnace connectionswith rich soap and water solution, commercialavailable bubble type leak detection fluid, or otherapproved means.

Do not use an open flame or other source of igni-tion for leak testing.

INLET GAS PRESSURE RANGE

NATURAL GAS PROPANE (LP)

Minimum 4.5 In. W.C. 11 In. W.C.

Maximum 13.8 In. W.C. 13.8 In. W.C.

G A S V A L V E

D R O P L E G

G R O U N D J O I N T U N I O N

M A Y B E I N S T A L L E D

I N S I D E O R O U T S I D E U N I T

T O G A S

S U P P L Y

T O G A S

S U P P L Y

E X T E R N A L M A N U A L

S H U T O F F V A L V E

CAUTION

Note: The furnace’s control system depends on correctpolarity of the power supply and a proper ground connec-tion. Refer to the furnace control diagnostics section forsymptoms of reversed power supply polarity

Use copper conductors only.

CAUTION

035-17429-000 REV B (0801)


ELECTRICAL CONTROL CONNECTIONS

Install the field-supplied thermostat. The thermostat instruc-tions for wiring are packed with the thermostat. With the ther-mostat set in the OFF position and the main electrical sourcedisconnected, complete the low-voltage wiring from the ther-mostat to the terminal board on the low-voltage transformer.Connect Class 2 control wiring for single stage thermostatwiring, refer to Figure 13 or for two stage thermostat wiringrefer to Figure 14.

Apply strain relief to thermostat wires passing through thecabinet

NOTE: Some electronic thermostats do not have adjustableheat anticipators. They may have other type cycle rate adjust-ments. Follow the thermostat manufacturer's instructions.

FIGURE 11 : UPFLOW MODELS (P*DU & G8D-UH)ELECTRICAL WIRING

FIGURE 12 : DOWNFLOW MODELS (P*DD &G8D-DN) ELECTRICAL WIRING

CLASS 2 SYSTEMCONTROL WIRINGTO THERMOSTAT

L1(HOT) N

GRD

BLKGRN

WHI

WIRING INSIDEJUNCTION BOX

BLK/BLK

WHI/WHI

GRN/GRN

BURNER COMPARTMENT

BLOWER COMPARTMENT

DOOR SWITCH

IGNITION MODULE

TRANSFORMER

JUNCTIONBOX

C R

Y

G W

COOL

HEAT

PARK

PARK

XFMR

LINE

HUM

EAC

XFMR

EAC

LINE

CIR

HUM

Y

B L K

H U M

E A C

B L K

� � �

� � �

� �

� � �

Set the heat anticipator in the room thermostat as shownbelow. Setting it lower will cause short cycles. Setting ithigher will cause the room temperature to exceed the set-point

Two-Stage ThermostatFirst Stage .4 Amps

Second Stage .1 Amps

Single Stage Thermostat .4 Amps

FIGURE 13 : FIELD WIRING FOR SINGLE STAGETHERMOSTAT

FIGURE 14 : FIELD WIRING FOR TWO STAGETHERMOSTAT

ROOM

THERMOSTAT

FURNACE

CONTROL

24 V COM. (IF REQ) B

G

Y

C

G

Y1

SINGLE-STAGE THERMOSTATCONNECTION DIAGRAM

RRH

RC

W1 W1

W2

FAN

24 V POWER

COOLING

HEAT

DELAYTIMER

BLUE

WHITE

TO AIRCONDITIONER

CONDENSING UNIT

ROOM

THERMOSTAT

FURNACE

CONTROL

TO AIRCONDITIONER

CONDENSING UNIT

24 V COMMON B

*

G

Y

C

G

Y1

TWO-STAGE THERMOSTATCONNECTION DIAGRAM

RRH

RC

W1

W2

W1

W2

FAN

24 V POWER

COOLING

HEAT (LOW)

HEAT (HIGH)

* Remove wires (blue & white) from timer

DELAYTIMER

BLUE

WHITE

035-17429-000 REV B (0801)


The 24-volt, 40 VA transformer is sized for the furnace com-ponents only, and should not be connected to auxiliarydevices such as humidifiers, air cleaners, etc. The trans-former may provide power for an air conditioning unit contac-tor.

SAFETY CONTROLS

Blower Door Safety Switch:This unit is equipped with anelectrical interlock switch mounted in the blower compart-ment. This switch interrupts all power at the unit when thepanel covering the blower compartment is removed.

Electrical supply to the unit is dependent upon the panel thatcovers the blower compartment being in place and properlypositioned.

Rollout Switch Controls:These controls are mounted on theburner assembly. If the temperature in the burner compart-ment exceeds its set point, the ignition control and the gasvalve are de-energized. This is a manual reset control andmust be reset before operation can continue.

The operation of this control indicates a malfunction in thecombustion air blower or a blocked vent pipe connection.

Pressure Switch:This furnace is supplied with two differen-tial pressure switches which monitor the flow of combustionproducts through the furnace and venting system. This switchde-energizes the ignition control module and the gas valve ifany of the following conditions are present:

1. Blockage of internal flue gas passageways.

2. Blockage of vent piping.

3. Failure of combustion air blower/motor.

Limit Control:The high temperature limit control is locatedon the furnace vestibule panel just to the right and below thegas valve. This is an automatic reset control and providesover temperature protection due to reduced airflow, such as adirty filter.

Auxiliary Limit:ControlsThese high temperature limit con-trols are located in the blower compartment, one on eachside on upflow/horizontal unit. Downflow units have a singlelimit mounted on the blower assembly. These are manualreset controls and provide high temperature protection whenthe unit is applied in the horizontal position.

Control Circuit Fuse:A 3 amp fuse is provided to protect the24 volt transformer from overload caused by control circuitwiring errors. This is an ATO 3, automotive type fuse and islocated in the unit wiring harness between the control trans-former and the furnace control.

START-UP AND ADJUSTMENTS

The initial start-up of the furnace requires the following addi-tional procedures.

1. When the gas supply is initially connected to the furnace,the gas piping may be full of air. In order to purge this air,it is recommended that the ground joint union be loos-ened until the odor of gas is detected. When gas isdetected, immediately retighten the union and check forleaks. Allow five minutes for any gas to dissipate beforecontinuing with the start-up procedure.

2. All electrical connections made in the field and in the fac-tory should be checked for proper tightness.

Blower and burner must never be operated withoutthe blower panel in place.

Main power supply to the unit must still be inter-rupted at the main power disconnect switch beforeany service or repair work is to be done to the unit.Do not rely upon the interlock switch as a mainpower disconnect.

CAUTION

CAUTION

035-17429-000 REV B (0801)


IGNITION SYSTEM CHECKOUT/ADJUSTMENT

1. Turn the gas supply ON at external manual shut-off valveand main gas valve.

2. Set the thermostat above the room temperature to callfor heat.

3. System start-up will occur as follows:

a. The ventor motor will start and operate on lowspeed. Shortly after ventor start-up, the hot surfaceignitor will glow for about 17 seconds.

b. After this warm-up cycle, the ignition module willenergize (open) the main gas valve on low fire forseven seconds.

NOTE: Burner ignition may not be satisfactory on first start-up due to residual air in gas line, or until gas pressure (mani-fold) is adjusted.

4. With the furnace in operation, paint the pipe joints andvalve gasket lines with a rich soap and water solution.Bubbles indicate a gas leak. Take appropriate steps tostop the leaks. If the leak persists, replace the compo-nent.

.

GAS VALVE OPERATION

The manual switch is a two-position (on-off) type. To turn thevalve on, move switch to the “ON” position. Refer to Figure15.

CHECKING GAS INPUT

1. Turn off all other gas appliances connected to gas meter.

2. With the furnace turned on, measure the time needed forone revolution of the hand on the smallest dial on themeter. A typical domestic gas meter usually has a 1/2 or1 cubic foot test dial.

3. Using the number of seconds for each revolution and thesize of the test dial increment, find the cubic feet of gasconsumed per hour. Refer to Table 5.

FIGURE 15 : GAS VALVES - (TOP) MANUALCONTROL KNOB (BOTTOM) REGU-LATOR ADJUSTMENTS

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�2��%��432 ��564�

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�&�)��$$�/�� 7

��3�

�4 3� ��4��28

LOW FIREREGULATORADJUSTMENT

SEAL SCREW

HIGH FIREREGULATORADJUST-

MENT

DO NOT omit this test! NEVER use a flame tocheck for gas leaks.

TABLE 5 : GAS RATE (CUBIC FEET PER HOUR)

SECONDS FOR ONE

REVOLUTION

SIZE OF TEST DIAL

1/2 CUBIC FOOT 1 CUBIC FOOT

10 180 360

12 150 300

14 129 257

16 113 225

18 100 200

20 90 180

22 82 164

24 75 150

26 69 138

28 64 129

30 60 120

32 56 113

34 53 106

36 50 100

38 47 95

40 45 90

42 43 86

44 41 82

46 39 78

48 37 75

50 36 72

52 35 69

54 34 67

56 32 64

58 31 62

60 30 60

CAUTION

035-17429-000 REV B (0801)


NOTE: To find the Btuh input, multiply the number of cubicfeet of gas consumed per hour by the BTU content of the gasin your particular locality. Contract your gas company for thisinformation, as it varies widely from city to city.

EXAMPLE: It is found by measurement that it takes 26 sec-onds for the hand to turn on the 1 cubic foot dial to make arevolution with only a 120,000 Btuh furnace running. Usingthis information, locate 26 seconds in the first column of Table5 on page 17.

Read across to the column headed 1 Cubic Foot where youwill see that 138 cubic feet of gas per hour are consumed bythe furnace at that rate. Multiply 138 by 850 (the BTU ratingof the gas obtained from the local gas company). The result is117,300 Btuh, which is close to the 120,000 Btuh rating of thefurnace.

If the actual input is not within 2% of the furnace rating, withallowance being made for the permissible range of the regu-lator setting (0.3 inches W.C.), replace the orifice spuds withspuds of the proper size.

ADJUSTMENT OF MANIFOLD GAS PRESSURE

The regulated outlet pressures, both low and high have beenfactory set. Additional pressure adjustment should not benecessary. If adjustment is necessary, set manifold pressureto the following specifications. After adjustment, check for

gas leakage.

High Pressure Adjustment

1. Turn off all electrical power to the system at main fuse orcircuit breaker. Close manual gas valve.

2. Attach a manometer to the outlet pressure tap of thevalve.

3. Turn on power and energize main and redundant (P.M.)solenoids as well as the HI terminal. Open the manualgas valve.

4. Remove high adjustment seal screw to expose the 3/32"adjustment screw. (Refer to Figure 15 on page 17)

5. To increase outlet pressure, turn the 3/32" set screwclockwise. To decrease outlet pressure, turn the setscrew counterclockwise. Adjust regulator until pressureshown on manometer matches the pressure specified onthe appliance rating plate.

6. Replace high adjustment seal screw and tightensecurely. Cycle the valve several times to verify regulatorsetting.

7. Once the correct gas pressures to the burners has beenestablished, turn the gas valve switch to OFF and turnthe electrical supply switch OFF; then, remove the pres-sure tap at the gas valve and re-install the plug using acompound (on the threads) resistant to the action of LPgases.

Low Pressure Adjustment

1. Adjust the thermostat so the furnace will operate at lowfire.

2. Refer to Figure 11 for the location of the pressure regula-tor adjustment cap and screw on main gas valve.

3. Remove low adjustment seal screw, see Figure 11.

4. To increase outlet pressure, turn the 3/32” set screwbelow the low adjustment seal screw clockwise. Todecrease outlet pressure, turn the set screw counter-clockwise. Adjust regulator until pressure shown onmanometer matches the pressure specified on the appli-ance rating plate.

5. Replace low adjustment seal screw and tighten securely.Cycle the valve several times to verify regulator setting.

6. Turn off gas and electricity and remove manometer andgas valve tap and replce the utlet pressure tap plug.

7. Turn the electrical and gas supplies back on, and withthe burners in operation, check for gas leakage aroundthe plug with a soap and water solution..

Be sure to relight any gas appliances that wereturned off at the start of this input check.

GAS MANIFOLD PRESSURE RANGE

NATURAL GAS PROPANE (LP)

LOW FIRE 1.6 In. W.C. 6.5 In. W.C.

HIGH FIRE 3.5 In. W.C. 10.0 In. W.C.

CAUTION

The manifold pressure must be checked with thescrew-off cap in place on the pressure regulator.

If manifold pressure is too high, an over-fire condi-tion exists which could cause heat exchanger fail-ure. If the manifold pressure is too low, sootingand eventual clogging of the heat exchanger couldoccur.

WARNING

035-17429-000 REV B (0801)


.

ADJUSTMENT OF TEMPERATURE RISE

The temperature rise, or temperature difference between thereturn air and the heated air from the furnace, must be withinthe range shown on the furnace rating plate and within theapplication limitations shown in Tables 3 or 4. After the tem-perature rise has been determined, the airflow (CFM) can becalculated.

After about 20 minutes of operation, determine the furnacetemperature rise. Take readings of both the return air and thesupply air in the ducts, about six feet from the furnace wherethey will not be affected by radiant heat.

Increase the blower speed to decrease the temperature rise;decrease the blower speed to increase the rise.

All direct-drive blowers have multi-speed motors. The blowermotor speed taps are located on the control module in theblower compartment. To change the blower speed, refer tothe unit wiring label and Figure 16.

You may select a heating speed and a cooling speed. Theymay be the same speed or a different speed.

To use the same speed tap for HI input heating and cooling,the HEAT HI terminal and COOL terminal must be connectedusing a jumper wire and connected to the desired motor lead.Place all unused motor leads on Park terminals (one is pro-vided.)

ADJUSTMENT OF FAN CONTROL SETTINGS

This furnace is equipped with a time-on/time-off heating fancontrol. The fan on-delay is fixed at 30 seconds. The fan off-delay is field adjustable from 60 to 180 seconds. The fan off isfactory set to 60 seconds. The fan-off setting must be longenough to adequately cool the furnace, but not so long thatcold air is blown into the heated space.

The fan-off timing and continuous fan speed setting may beadjusted by setting the option switches located (Refer to Fig-ure 16) on the control board as follows:

Be sure that the gas valve pressure regulator capis replaced.

Do not energize more than one motor speed at atime or damage will result.

WARNING

CAUTION

FIGURE 16 : TYPICAL HEAT/COOL SPEED TAPCONNECTIONS

WHITE-RODGERS CONTROL

To Delay Fan-Off By: Set Switch1 2

60 Sec. On On

90 Sec. On Off

120 Sec. Off On

180 Sec. Off Off

Continuous FanSetting

Set Switch 3

HEAT LO

COOL

COOL

HEA T L O

HEA T HI

MOTOR LEADS

OFF ON

W1 W2 Y R G B

FAN OFF

ADJUSTMENT

SWITCHES

PARK

BLU-MED SPEED

RED - LOW SPEED

BLK-HIGH SPEED

BLK

RED

BLU

1

3

035-17429-000 REV B (0801)


ACCESSORY CONNECTIONS

The furnace control will allow power switching control of vari-ous accessories. Refer to Figure 17 for connection details.

Electronic Air Cleaner Connection

Two 1/4" spade terminals (EAC and EAC N) for electronic aircleaner connections are located on the control board. Theterminals provide 115 VAC (1.0 amp maximum) during circu-lating blower operation. A high voltage connection lead isrouted to the junction box for easy connection.

Humidifier Connection

Two 1/4" spade terminals (HUM and HUM N) for humidifierconnections are located on the control board. The terminalsprovide 115 VAC (1.0 amp maximum) during heating systemoperation. A high voltage connection lead is routed to the

junction box for easy connection.Note:Wires for Electronic Air cleaner and Humidifier or anyother accessories must be routed through junction box.

FURNACE ACCESSORIES .

FIGURE 17 : ACCESSORY CONNECTIONS

HUM

EAC

EAC

HUM

115 VOLTELECTRONICAIR CLEANER

EAC HOT

HUM HOT

BLK

BLK

WHI

WHI

115 VOLTHUMIDIFIER

SWITCHEDCIRCUITS

NEUTRALS

ELECTRICAL

*ET03700324 Thermostat, One-stage Heat/One-stage Cool, Non-Programmable

*ET03700124 Thermostat, One Stage heat/ One Stage Cool, Deluxe Programmable

*ET0770010124 Thermostat, Two-stage Heat/Two-stage Cool, Non-Programmable

*ET03700024 Thermostat, Two-stage Heat/Two-stage Cool, Programmable

NON-ELECTRICAL

1NP0480 Propane Conversion Kit

1SR0302BK External Side Filter Rack (6-Pack)

1BR0314 External Bottom Filter Rack - Cabinet “A”

1BR0317 External Bottom Filter Rack - Cabinet “B”

1BR0321 External Bottom Filter Rack - Cabinet “C”

1PS0313 High Altitude Pressure Switch Kit

1PS0314 High Altitude Pressure Switch Kit

1CB0314 Combustible Floor Base - Cabinet “A”

1CB0317 Combustible Floor Base - Cabinet “B”

1CB0321 Combustible Floor Base - Cabinet “C”

1CK0604 Masonry Chimney Kit for 4” Vent

035-17429-000 REV B (0801)


TABLE 6: BLOWER PERFORMANCE - CFM - UPFLOW/HORIZONTAL (WITHOUT FILTER)NOTE: Data below reflects air flows with single return opening, either left or right side or bottom.

MODELS: P*DU/

G8D-UH/L8D-UH*SPEED

TAP

EXTERNAL STATIC PRESSURE, INCHES W.C.

0.10 0.20 0.30 0.40 0.50 0.60 0.70 0.80 0.90 1.00

60 / 48 / 1200 / "A"†

80 / 64 / 1200 / "A"†

HIGH 1580 1530 1470 1405 1330 1245 1150 1045 890 650

MED-HIGH 1110 1100 1075 1060 1030 980 920 835 680 520

MED-LOW 845 840 830 815 790 750 670 595 480 320

LOW 675 665 660 645 620 585 530 455 360 255

100 / 80 / 1200 / "B"

HIGH 1675 1645 1595 1530 1465 1385 1280 1155 1025 810

MED 1270 1260 1250 1240 1215 1185 1125 1035 910 695

LOW 955 950 945 935 920 905 865 810 685 510

80 / 64 / 1600 / "B"†

HIGH 1970 1935 1900 1850 1795 1735 1660 1590 1495 1395

MED 1445 1435 1425 1415 1405 1375 1350 1300 1240 1160

LOW 1245 1235 1225 1215 1205 1190 1170 1135 1090 995

120 / 96 / 1600 / "C"

HIGH 2040 1975 1925 1855 1780 1695 1610 1505 1380 1225

MED 1725 1685 1650 1610 1555 1500 1425 1340 1220 1075

LOW 1365 1355 1325 1290 1265 1250 1210 1140 1045 940

100 / 80 / 2000 / "C"†

120 / 96 / 2000 / "C"†

HIGH 2400 2320 2275 2200 2115 2025 1930 1825 1700 1570

MED 2050 2025 1980 1930 1855 1805 1720 1635 1530 1400

LOW 1690 1675 1660 1630 1610 1560 1500 1430 1330 1225

NOTE: Data below reflects airflows with two return openings - two sides or one side and bottom.

100 / 80 / 2000 / "C"†

120 / 96 / 2000 / "C"†

HIGH 2405 2340 2275 2210 2130 2050 1955 1840 1725 1600

MED 2005 1990 1965 1935 1880 1815 1725 1635 1535 1410

LOW 1655 1640 1625 1610 1585 1540 1485 1420 1340 1235

*. Input / Output / CFM / Cabinet Type (A = 14-1/2, B = 17-1/2, C = 21, D = 24-1/2)• Airflow is expressed in standard cubic feet per minute.• Motor voltage at 115V†. Indicates LoNox models available

035-17429-000 REV B (0801)


FILTER PERFORMANCE

The airflow capacity data published in Blower PerformanceTables on pages 21 and 22, represents blower performanceWITHOUT filters. To determine the approximate blower perfor-mance of the system, apply the filter drop value for the filterbeing used or select an appropriate value from the Table 8.

NOTE: The filter pressure drop values in Blower Performance-Tables are typical values for the type of filter listed and shouldonly be used as a guideline. Actual pressure drop ratings foreach filter type vary between filter manufacturer.

TABLE 7: BLOWER PERFORMANCE CFM - DOWNFLOW (WITHOUT FILTER)NOTE: Data below reflects air flows with single return opening, either left or right side or bottom.

MODELS: P*DD/

G8D-DN* SPEED TAPEXTERNAL STATIC PRESSURE, INCHES W.C.

0.10 0.20 0.30 0.40 0.50 0.60 0.70 0.80 0.90 1.00

60 / 48 / 1200 / "A"80 / 64 / 1200 / "A"

HIGH 1580 1540 1475 1405 1305 1230 1130 1015 855 695

MED-HIGH 1140 1125 1110 1075 1035 980 920 815 700 570

MED-LOW 870 860 840 815 770 725 675 600 530 425

LOW 695 675 655 635 610 575 530 470 400 290

100 / 80 / 1200 / "B"

HIGH 1775 1720 1660 1585 1510 1420 1315 1195 1055 865

MED 1380 1360 1350 1330 1280 1230 1150 1050 920 760

LOW 1030 1015 1000 985 965 950 895 805 710 595

80 / 64 / 1600 / "B"

HIGH 2110 2050 1995 1910 1840 1780 1690 1610 1515 1415

MED 1895 1860 1825 1765 1700 1630 1560 1495 1410 1310

LOW 1690 1675 1660 1605 1550 1490 1440 1360 1280 1200

115 / 92 / 2000 / "C"

HIGH 2515 2440 2355 2265 2190 2100 1990 1875 1740 1600

MED 2085 2070 2040 2000 1925 1850 1765 1660 1555 1430

LOW 1720 1710 1695 1685 1625 1580 1515 1440 1345 1215

*. Input / Output / CFM / Cabinet Width (A = 14-1/2, B = 17-1/2, C = 21, D = 24-1/2)• Airflow is expressed in standard cubic feet per minute.Motor voltage at 115V

TABLE 8: FILTER PERFORMANCE - PRESSURE DROP INCHES W.C.

Airflow Range

Minimum Opening Size

(in.2)

Filter Type

Disposable Hogs Hair* Pleated

1 Opening 2 Openings 1 Opening 2 Openings 1 Opening 2 Openings 1 Opening 2 Openings

0 - 750 230 0.01 0.01 0.15

751 - 1000 330 0.05 0.05 0.20

1001 - 1250 330 0.10 0.10 0.20

1251 - 1500 330 0.10 0.10 0.25

1501 - 1750 380 658 0.15 0.09 0.14 0.08 0.30 0.17

1751 - 2000 380 658 0.19 0.11 0.18 0.10 0.30 0.17

2001 & Above 463 658 0.19 0.11 0.18 0.10 0.30 0.17

*. Hogs Hair Filters are the type supplied with furnace (if supplied).

035-17429-000 REV B (0801)


APPLYING FILTER PRESSURE DROP TODETERMINE SYSTEM AIRFLOW

To determine the approximate airflow of the unit with a filter inplace, follow the steps below:

1. Select the filter type.

2. Select the number of return air openings or calculate thereturn opening size in square inches to determine theproper filter pressure drop.

3. Determine the External System Static Pressure (ESP)without the filter.

4. Select a filter pressure drop from the table based uponthe number of return air openings or return air openingsize and add to the ESP from Step 3 to determine thetotal system static.

5. If total system static matches a ESP value in the airflowtable (i.e. 0.20, 0.60, etc,) the system airflow corre-sponds to the intersection of the ESP column and Model/Blower Speed row.

6. If the total system static falls between ESP values in thetable (i.e. 0.58, 0.75, etc.), the static pressure may berounded to the nearest value in the table determining theairflow using Step 5 or calculate the airflow by using thefollowing example.

Example: For a 120,000 Btuh furnace with 2 return openingsand operating on high speed blower, it is found that total sys-tem static is 0.58" w.c. To determine the system airflow, com-plete the following steps:

1. Obtain the airflow values at 0.50" & 0.60" ESP.

Airflow @ 0.50": 2130 CFMAirflow @ 0.60": 2050 CFM

2. Subtract the airflow @ 0.50" from the airflow @ 0.60" toobtain airflow difference.

2050 - 2130 = -80 CFM

3. Subtract the total system static from 0.50" and divide thisdifference by the difference in ESP values in the table,0.60" - 0.50", to obtain a percentage.

(0.58 - 0.50) / (0.60 - 0.50) = 0.8

4. Multiply percentage by airflow difference to obtain airflowreduction.

(0.8) x (-80) = -64

5. Subract airflow reduction value from airflow @ 0.50" toobtain actual airflow @ 0.58" ESP.

2130 - 64 = 2066

OPERATION AND MAINTENANCE

SEQUENCE OF OPERATION

The following describes the sequence of operation of the fur-nace. Component locations can be seen on the schematicwiring diagrams seen 30 or 31. The event schedule is locatedin Figure 18 on page 29.

CONTINUOUS BLOWER

On cooling/heating thermostats with fan switch, when the fanswitch is set in the ON position, a circuit is completedbetween terminals R and G of the thermostat. The blowerspeed on which the continuous fan operates is field select-able to either HEAT LO or COOL . Refer to “Adjustment ofFan Control Settings” on page 19, for instructions on how toselect speeds.

INTERMITTENT BLOWER - COOLING

On cooling/heating thermostats with fan switch, when the fanswitch is set in the auto position and the thermostat calls forcooling, a circuit is completed between the R, Y and G termi-nals. The motor is energized through the cool fan terminaland runs on the selected speed. The fan off setting is fixed at60 seconds for SEER enhancement.

HEATING OPERATIONAL SEQUENCE

Two State Thermostat

The ignition control in this furnace is unique to thisproduct. The control allows for a 24 volt or a 115 voltcirculator input/output. This allows for the replacementof the variable speed motor with a multi-speed PSCmotor in the event a variable speed motor is not avail-able at the time of servicing.

In a typical system, a call first stage heat is initiated byclosing the W1 thermostat contacts. The inducerblower is energized at high speed and the control waitsfor the low pressure switch contacts to close. Theinducer blower is energized at low speed and the 120VAC silicon carbide ignitor is powered.

Label all wires prior to disconnecting when servic-ing controls. Wiring errors can cause improper anddangerous operation. Verify proper operation afterservicing.

CAUTION

035-17429-000 REV B (0801)


At the end of the ignitor warm-up time, the first stage ofthe two stage gas valve is energized (low fire). Flamemust be detected within 7 seconds. If flame isdetected, the delay-to-fan-on period begins. After thedelay-to-fan-on period ends, the circular fan is ener-gized at low heat speed and the air cleaner and humid-ifier are energized.

A call for second stage heat (W1 and W2) after a callfor first stage heat will energize the inducer at highspeed and energize the circulator at high heat speed.The circulator will energize at high heat speed after 30seconds with a call for second stage heat. If the fur-nace has been operating in first stage heat for morethan 30 seconds and the control receives a call for sec-ond stage heat, the blower will immediately switch tohigh speed. The second stage pressure switch con-tacts will close and energize the second stage gasvalve (high fire).

If a call for second stage heat occurs at the same timeas a call for first stage heat, the second stage heat isenergized immediately after flame rectification issensed on first stage.

When the second stage of the thermostat is satisfied,the inducer motor is reduced to low speed and the 2ndstage gas valve is de-energized to first stage. The cir-culator remains on high heat speed for 30 secondsthen de-energizes to low heat speed.

When the first stage of the thermostat is satisfied, thegas valve is de-energized and the heat delay to fan offbegins timing. The inducer will postpurge for an addi-tional 15 seconds, then the inducer and humidifier willde energize. Upon completion of the heat delay-to-fan-off, the circulator and air cleaner are deenergized. Forcontrol timing, refer to Figure 15 on page 20.

If flame is not detected during the trial for ignitionperiod, the gas valve is de energized, the ignitor isturned off and the ignition control goes into the “re-entry” sequence.

The “re-entry” sequence provides a 60 second waitwith inducer interpurge following an unsuccessful igni-tion attempt (flame not detected). After this wait, theignition sequence is restarted with an additional 10seconds of ignitor warm-up time. Two retries will beattempted before the control goes into system lockout.If flame is established for more than 10 seconds afterignition, the ignition controller will clear the ignitionattempt (or retry) counter.

If flame is detected, then lost, the ignition control willrepeat the initial ignition sequence. After 5 attempts tosustain flame, the control will go into system lockout.

During burner operation, a momentary loss of power of50 milliseconds or longer will de energize the main gasvalve. When power is restored, the gas valve willremain de energized and a restart of the ignitionsequence will begin immediately.

A momentary loss of gas supply, flame blowout, or ashorted or open condition in the flame probe circuit willbe sensed within 0.8 seconds. The gas valve will deenergize and the control will restart the ignitionsequence.

Recycles will begin and the burner will operate nor-mally if the gas supply returns, or the fault condition iscorrected, before the last ignition attempt. Otherwise,the control will go into system lockout.

If the control has gone into system lockout, it may bepossible to reset the control by a momentary powerinterruption of one second or longer. Refer to the “FUR-NACE CONTROL DIAGNOSTICS” on page 27 of thisinstruction for reset information.

Single Stage Thermostat

If a single stage thermostat is used, the unit will be con-trolled through the CFM Timer board timer adjust pins(refer to Figure 9 on page 12). For the furnace to oper-ate on High Fire the timer jumper must be placed onthe 10, 15 or 20 minute adjustment terminals. On a callfor heat the unit will operate on low fire as detailedabove. If the heating requirements cause the cycle toexceed the jumper settings, the high fire timer will ener-gize the second stage heat. The second stage opera-tion will function as detailed above. The heating cyclewill be completed in high fire operation. If the timerjumper is in the “TIME OFF” position with a single-stage thermostat, the unit will stay in low fire operation.

Hot Surface Ignition System

Do not attempt to light this furnace by hand (with amatch or any other means). There may be apotential shock hazard from the components of thehot surface ignition system. The furnace can onlybe lit automatically by its hot surface ignition sys-tem.

WARNING

035-17429-000 REV B (0801)


MAINTENANCE

Air Filters

The filters should be checked periodically for dirt accumula-tion. Dirty filters greatly restrict the flow of air and overburdenthe system.

Clean the filters at least every three months. On new con-struction installations, check the filters every week for the firstfour weeks. Inspect the filters every three weeks after that,especially if the system is running constantly.

All filters supplied with the furnace are the high-velocity,cleanable type. Clean these filters by washing in warm water.Make sure to shake all the water out of the filter and have itreasonably dry before installing it in the furnace. Whenreplacing filters, be sure to use the same size and type asoriginally supplied.

Upflow / Horizontal Installations - Filter Removal

1. Turn off electrical power supply to the furnace at discon-nect switch. Remove access doors.

2. In the blower compartment disengage the looped end ofthe filter retainer wire from the front edge of the cabinet.The wire will now pivot on the hinged ends at the rear ofthe cabinet.

3. Remove the filter and follow the cleaning instructionsabove. DO NOT remove the filter stiffener rods, if pro-vided.

4. When reinstalling the filter, be sure the filter completelycovers the cabinet opening and is secured in place bythe wire retainer.

5. To reassemble, reverse the procedure, restore power tothe furnace and verify operation.

Downflow Installations - Filter Removal


2. Filters are installed in the plenum area above the blowerassembly. Filters rest against the side of the plenum walland are supported in the middle by a frame. Lift filterslightly to dislodge and remove for service.

3. Remove the filter and follow the cleaning instructionsabove. DO NOT remove the filter stiffener rods, if pro-vided. When reinstalling the filter(s) be sure it completelycovers the plenum opening.


Lubrication

Blower and ventor motors in these furnaces are permanentlylubricated and do not require periodic oiling.

BLOWER CARE

Even with good filters properly in place, blower wheels andmotors will become dust laden after long months of opera-tion. The entire blower assembly should be inspected annu-ally. If the motor and wheel are heavily coated with dust, theycan be brushed and cleaned with a vacuum cleaner.

The procedure for removing the direct drive blower assemblyfor cleaning is as follows:

Upflow / Horizontal Installations


2. Remove the two auxiliary limit wires on the left side ofthe blower deck inside the blower compartment.

3. Remove blower assembly mounting screws and slide theblower assembly out of the slots in the deck. If the twoshipping screws were not previously removed, alsoremove and discard these two screws located on eachfront corner of the blower assembly.

4. Note the wire/terminal location and then remove theblower wiring from the furnace control. Remove the pro-tective boot and disconnect run capacitor wires. Removethe screws securing the electrical panel to the blowerhousing. Pull blower assembly out of the unit. Whencleaning or servicing the blower assembly, DO NOTremove or change the balance clips on the blower wheel.


Downflow Installations

1. Disconnect the electrical supply to the furnace andremove the access doors.

2. Remove the two wires leading to the auxiliary limit switchmounted on top of the blower housing.

3. Remove the four top panel screws and lift the top panelenough to disengage and remove the flue chase assem-bly. Be sure to first remove the screw attaching the ventpipe to the flue collar.

When replacing filters DO NOT use a type withexcessively high pressure drop. Some high effi-ciency filters available will cause the furnace tooperate improperly and could result in a safetyhazard.

WARNING

035-17429-000 REV B (0801)


4. Remove blower assembly mounting screws and slide theblower assembly out of the slots in the deck. If the twoshipping screws were not previously removed, alsoremove and discard these two screws located on eachfront corner of the blower assembly.

5. Note the wire/terminal location and then remove theblower wiring from the furnace control. Remove the pro-tective boot and disconnect run capacitor wires. Removethe screws securing the electrical panel to the blowerhousing. Pull blower assembly out of the unit. Whencleaning or servicing the blower assembly, DO NOTremove or change the balance clips on the blower wheel.


Burner Removal/Cleaning

The main burners should be checked periodically for dirtaccumulation.

If cleaning is required, follow this procedure:

1. Turn off the electrical power to the unit and turn off gassupply at the shutoff valve.

2. Remove the blower and burner compartment accessdoors.

3. Unplug ignitor from the wire harness and remove theignitor/bracket assembly from the burner air shield. Han-dle the ignitor carefully as it is fragile and easily broken.

4. Note the location and then disconnect the sensor androllout switch wires located on the top of the air shieldand remove the shield.

5. Remove the two screws securing each burner to theburner assembly. Note the orientation of the burner(flanged side down) before removing. Burners may becleaned by rinsing in hot water or by using a vacuumcleaner.


CLEANING THE HEAT EXCHANGER

Lower Heat Exchanger Access

1. Turn off the electrical power to the unit and turn off gassupply at the shutoff valve.

2. Remove the blower and burner compartment accessdoors. Disconnect the gas supply piping at the union topermit removal of the entire burner and gas controlassembly from the vestibule panel. Use the wrench bosson the gas valve when removing or installing this piping.

3. Unplug the ignitor from the wire harness. Disconnectsensor and rollout switch wires located on top of the airshield. Identify and note the location of all leads for ease

of reinstallation. Also disconnect the wires at the siderollout switches (upflow only) and the gas valve wires.

4. Remove the screws holding the burner assembly to thevestibule panel and remove this assembly. Handle theassembly carefully since it contains the ignitor which isfragile and easily broken. The lower portion of the heatexchanger will now be exposed. To clean the burnerassembly, use a vacuum cleaner, or remove the burnersas outlined in burner cleaning, and clean in hot water.

Upper Heat Exchanger Access

1. Perform steps 1-4 above.

2. Disconnect vent piping from the vent motor assembly atthe top panel on the furnace (upflow only). On downflowmodels, the vent pipe is attached to the vent motor out-let. Remove this screw before proceeding.

3. Unplug the vent motor wires and ground wire. Removethe pressure switch tubing at the tap on the vent motorhousing.

NOTE: It is recommended that replacement gaskets be avail-able before removing vent motor.

4. Remove six mounting screws that hold the vent motor tothe restrictor plate. The surface is gasketed and gasketcan be reused if it is carefully removed. It is necessary toremove this assembly to gain access to the restrictorplate mounting holes. The assembly may be vacuumed ifcleaning is necessary. If any vent assembly parts aredamaged, replace with an entire new assembly (exceptfor gaskets).

5. Remove the perimeter screws attaching the restrictorplate assembly to the vestibule panel. The surface isalso gasketed. The assembly, including the flue baffleplate (rear) may be vacuumed or cleaned with hot waterif necessary.

6. The upper portion of the heat exchanger is now accessi-ble. With a long flexible wire brush, clean inside eachtube at both the top and bottom. The brush must passaround the rear heat exchanger tubes. Vacuum loosescale and dirt from each tube.

7. Clean - Replace all components in reverse order. Regas-ket all surfaces which required a gasket. Reconnect allwiring. Reattach vent pipe and gas supply lines beforerestoring service to furnace. Restore electrical power,check gas supply piping for leaks, then verify furnaceoperation.

TROUBLESHOOTING

The following visual checks should be made before trouble-shooting:

1. Check to see that the power to the furnace and the igni-tion control module is ON.

035-17429-000 REV B (0801)


2. The manual shutoff valves in the gas line to the furnacemust be open.

3. Make sure all wiring connections are secure.

4. Review the sequence of operation.

Start the system by setting the thermostat above the roomtemperature. Observe the system's response. Then use thetroubleshooting section in this manual to check the system'soperation.

FURNACE CONTROL DIAGNOSTICS

The furnace has built-in, self diagnostic capability. If a systemproblem occurs, a fault code is shown by a blinking LED. It islocated behind a clear view port in the blower compartmentdoor. DO NOT remove the furnace blower compartmentpanel OR turn off furnace power as either action will clear thecontrol's memory of the fault.

The control continuously monitors its own operation and theoperation of the system. If a failure occurs, the LED will indi-cate the failure code. If the failure is internal to the control, thelight will stay on continuously. In this case, the entire controlshould be replaced as the control is not field repairable.

If the sensed failure is in the system (external to the control),the LED will flash in the following flash-pause sequences toindicate failure status.

Flash sequence codes 2 thru 8 are as follows. LED will turnon for 1/4 second and off for 1/4 second. This pattern will berepeated the number of times equal to the code. For exam-ple, six on flashes equals a number 6 fault code.All flashcode sequences are broken by a 2 second off period.

CONTINUOUS FLASHING (1 sec on - 1 sec off):This indi-cates that flame was sensed when there was not a call forheat. With this fault code the control will turn on both theinducer motor and supply air blower. This fault would typicallybe caused by a gas valve that leaks through or is slow clos-ing.

2 FLASH:This indicates that the normally open pressureswitch contacts are stuck in the closed position. The controlconfirms these contacts are open at the beginning of eachheat cycle. This would indicate a faulty pressure switch ormis-wiring.

3 FLASH:This indicates the normally open pressure switchcontact did not close at the beginning of the heat cycle. Thiscould be caused by a number of problems; faulty inducer,blocked vent pipe, broken pressure switch hose or faultypressure switch.

4 FLASH:This indicates that a primary limit, or auxiliary limit,or rollout limit switch has opened its normally closed contacts.With this fault code the control will operate the supply airblower and inducer. This condition may be caused by: dirty fil-ter, improperly sized duct system, incorrect blower speed set-ting, incorrect firing rate or faulty blower motor. The rolloutcontrol is manually reset. If it has opened, check for propercombustion air, proper inducer operation, primary heatexchanger failure or burner problem. Be sure to reset theswitch after correcting the failure condition.

6 FLASH:This indicates that after the unit was operating, thepressure switch opened 4 times during the call for heat. Thiscould be caused by a number of problems; blocked vent orchimney, faulty inducer, cracked pressure switch hose.

7 FLASH:This fault code indicates that flame could not beestablished. This no-light condition occurred 3 times duringthe call for heat before locking out. This may be caused bylow gas pressure, faulty gas valve, faulty hot surface ignitor,reversed line polarity, or burner problem.

8 FLASH:This fault is indicated if the flame is lost 5 timesduring the heating cycle. This could be caused by low gaspressure or faulty gas valve.

LED ON CONSTANTLY:This indicated an internal fault in thefurnace control discovered during its self-check procedure.Replace the control.

IGNITION CONTROL (P/N 031-01290-000)Normal flame sense current is approximately

2.4 microamps DC (υa)

Low flame signal control lockout point is

0.15 microamps DC (υa)

POWER SUPPLY POLARITY -If the power supply polarity is reversed, the following unitoperation will occur. On a call for heat, the inducer willrun, the HSI will glow and the gas valve will energize andthe burners will ignite. The burners will immediatelyextinguish and the unit will recycle. This will occur 3times and then the unit will lockout. A “7” flash code willbe displayed. This code means the flame could not beestablished. This occurs because the control cannotsense flame with the power supply polarity reversed.

035-17429-000 REV B (0801)


60 MINUTE AUTOMATIC RESET FROM LOCKOUT(Applies to Fault Codes 6, 7 & 8):This control includes awatchdog type circuit that will reset from a lockout conditionafter 60 minutes. This provides protection to an unoccupiedstructure if a temporary conditions exists causing a unit mal-function. An example would be a low incoming gas supplypressure condition preventing unit operation. When the gaspressure was restored, at some point the watchdog wouldrestart the unit and provide heat for the house.

NOTE: The control will blink one time when initially powered.This is normal and not an indication of any malfunction.

Never jump pressure switch to allow furnace oper-ation. To do so will allow furnace to operate underpotentially hazardous conditions.

Do not try to repair controls. Replace defectivecontrols with UPG Source 1 Parts.

Never adjust pressure switch to allow furnaceoperation.

WARNING

035-17429-000 REV B (0801)


FIGURE 18 : SEQUENCE OF OPERATION

HIGH LIMIT

W1 SIGNAL

PRESSURE SWITCH

HSI

MAIN VALVE

FLAME SENSE

CLOSED

OPEN

ON

OFF

ON

OFF

OPEN

CLOSED

ON

OFF

ON

OFF

PRESENT

ON

OFF

HSIWARM

UP17 SEC.

INTER-PURGE60 SEC.

IGNITIONACTIVATION

PERIOD4 SEC.

IGNITIONDEACTIVATION

PERIOD3 SEC.

HSIWARM

UP27 SEC.

HEAT FANDELAY ON

30 SEC.

BURNTIME

POSTPURGE15 SEC.

HEAT FAN DELAY OFFSELECTABLE

60, 90, 120, 180 SEC.TRIAL FORIGNITION

7 SEC

ABSENT

1ST STAGE

LOW STAGE

W2 SIGNAL

ON

OFF

HIGH INDUCER

HIGHHEATOFFDELAY30 SEC.

ON

OFF

ON

OFF

ON

OFF

CALL HIGH HEAT AFTER LOW HEAT IS ESTABLISHED

2ND STAGE

LOWINDUCER

LOW CIRCULATORHEAT SPEED

IST STAGE

NOTE: 1) THIS DIAGRAM SHOWS TWO IGNITION ATTEMPTS

HIGH STAGE PRESSURESWITCH AND 2ND STAGE

MAIN VALVE

CIRCULATOR HIGHHEAT SPEED

2) TIMING LENGTHS ARE NOT TO SCALE

Low pressureswitch closerecognition

035-17429-000 REV B (0801)


WIRING DIAGRAM - UPFLOW / HORIZONTAL MODELS (P*DU / G8D-UH & L8D-UH)NOTE: The furnace’s control system depends on correct polarity of the power supply.

NO

TE

8S

EE

LS1

SS

1R

OS

3

NO

TE

8S

EE

RE

D

SS

1

LS1

RO

S3

TOD

W2G

G

Y W1R B

R

HE

AT

/CO

OL

TH

ER

MO

ST

AT

ON

AU

TO

Y

CO

OL

HE

AT

OF

F

W

1LP

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RO

S3

RO

S3

LOW

HE

AT

5S\5P2

ST

AG

E

VA

LVE

MA

IN

LIN

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0VA

C.

BLK

BLK

EA

CH

UM

BLU

WH

T

TIM

ER

ON

D

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GR

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M

EA

C

L C

A A

R V

TU 0

E 2

N

1

CAV021TOH

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BLK

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T

OR

N

BLK

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T

BLU

WHT

BLK

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OA

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LAY

CO

NT

AC

TS

ON

IGN

ITIO

N

XF

MR

RE

DY

EL

BLU

BLK

RE

DY

EL

BLU

BLK

1200

4

1200

3G

RD

GR

N

GR

D

LIN

E

C

2LP

NO

NOC

1LP

BLO

WE

R S

PE

ED

CH

AR

TC

ON

NE

CT

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DIA

GR

AM

6. M

OT

OR

S A

RE

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ER

EN

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PR

OT

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D.

5. P

RO

VID

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ISC

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S F

OR

ALL

PO

WE

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UP

PLI

ES

.

4. A

LL R

EP

LAC

EM

EN

T C

OM

PO

NE

NT

S M

US

T B

E P

RO

PE

RLY

GR

OU

ND

ED

.

3. C

ON

NE

CT

OR

S S

UIT

AB

LE F

OR

CO

PP

ER

CO

ND

UC

TO

RS

ON

LY.

H

AV

ING

A T

EM

PE

RA

TU

RE

RA

TIN

G O

F A

T L

EA

ST

221

ßF

(10

5ßC

).

MU

ST

BE

RE

PLA

CE

D, I

T M

US

T B

E R

EP

LAC

ED

WIT

H W

IRIN

G M

AT

ER

IAL

2. IF

AN

Y O

F T

HE

OR

IGIN

AL

WIR

E A

S S

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PLI

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H T

HE

FU

RN

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E

(C

) LO

CA

L O

R C

ITY

CO

DE

S.

(B

) C

AN

AD

IAN

ELE

C. C

OD

E (

CE

C)

AN

D/O

R1.

ALL

FIE

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IRIN

G P

ER

: (A

) N

AT

ION

AL

ELE

C. C

OD

E (

NE

C)

AN

D/O

R

FIE

LD C

ON

NE

CT

ION

HU

MH

UM

EA

CE

AC

EA

C

HU

MID

IFIE

R

BLO

WE

RM

OT

OR

CO

OL

HI H

EA

T

1RC

80%

UP

FLO

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IZO

NT

AL

TW

O-S

TA

GE

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RN

AC

E

RE

LAY

IGN

ITE

R

GV

GR

D

DO

OR

SW

ITC

H N

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W

ELE

ME

NT

AR

Y D

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M

PO

WE

R S

UP

PLY

120

-1-6

0S

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NO

TE

1

GR

D

DS

CNO

CO

M12

0V

24V

SE

C

PR

I

1T (

40V

A)

VE

NT

OR

MO

TO

R

IGN

NO

TE

S:

LEG

EN

D

SS

1 S

PIL

L S

WIT

CH

(C

HIM

NE

Y K

IT)

RO

S4

RO

LL O

UT

SW

ITC

H T

OP

LE

FT

(6

& 7

CE

LL O

NLY

)

T

OP

RIG

HT

(5

& 7

CE

LL)

RO

S3

RO

LL O

UT

SW

ITC

H T

OP

MID

DLE

(2-

5 C

ELL

) R

OS

2 R

OLL

OU

T S

WIT

CH

RIG

HT

SID

E R

OS

1 R

OLL

OU

T S

WIT

CH

LE

FT

SID

ELS

2,3

AU

XIL

AR

Y L

IMIT

SW

ITC

H O

N B

LOW

ER

DE

CK

LS

1 P

RIM

AR

Y L

IMIT

SW

ITC

HP

5/S

5 3

PIN

PLU

G &

SO

CK

ET

ON

VA

LVE

P4/

S4

3 P

IN P

LUG

& S

OC

KE

T A

T IN

DU

CE

R M

OT

OR

P3/

S3

2 P

IN P

LUG

& S

OC

KE

T A

T H

OT

SU

RF

AC

E IG

NIT

OR

P2/

S2

5 P

IN P

LUG

& S

OC

KE

T O

N IG

N. C

ON

TR

OL

BO

AR

DP

1/S

1 1

2 P

IN P

LUG

& S

OC

KE

T O

N IG

N. C

ON

TR

OL

BO

AR

D I

GN

HO

T S

UR

FA

CE

IGN

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R

GV

GA

S V

ALV

E

DS

DIS

CO

NN

EC

T S

WIT

CH

- C

AU

TIO

N -

OP

EN

ALL

DIS

CO

NN

EC

TS

BE

FO

RE

SE

RV

ICIN

G T

HIS

UN

IT

1T

TR

AN

SF

OR

ME

R, 4

0VA

1RC

RU

N C

AP

AC

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P P

RE

SS

UR

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W, S

EC

ON

D S

TA

GE

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ES

SU

RE

SW

, FIR

ST

ST

AG

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FU

SE

IDE

NT

IFIE

D R

UN

CA

PA

CIT

OR

24V

CO

NN

EC

TIO

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OO

M T

HE

RM

OS

TA

T

FA

CT

OR

Y W

IRIN

G A

ND

DE

VIC

ES

----

- F

IELD

WIR

ING

AN

D D

EV

ICE

S

JU

MP

ER

ED

. H

I AN

D C

OO

L T

ER

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ALS

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NIT

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HIP

PE

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ITH

HE

AT

P1/

S1

BLO

WE

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PE

ED

FO

R D

ES

IRE

DS

EE

CH

AR

T

IG

NIT

ER

HO

T S

UR

FA

CE

WH

T

WH

T

BLK

WH

T

BLK

12

13 P3/

S3

P4/

S4

BR

N

GRN

GR

N

FLA

ME

SE

NS

OR

BLU

2LP

120V

AC

120V

CO

M 24V

SE

C

PR

I

N.O

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DO

OR

CNO

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LOW

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OT

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R

WH

T (

NE

UT

)

YE

L (M

ED

LO

W)

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BR

N

BLK

(H

I)

HE

AT

HI

1 23

456

789

101112P

RP

P2/S2

XF

MR

LIN

E

CIR

4321

HE

AT

LO

PA

RK

CO

OL

WH

T

PA

RK

LOW

HE

AT

HIG

HH

EA

TC

OO

LC

FM

CE

LL

035-

1743

1-00

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5B

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BR

N

RE

D

BR

N

RE

D

WH

T

BLK

RE

D

WH

T

BLK

BLU

BR

N

3A

1ST

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2ND

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AG

E

3A

RO

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RO

S2

LS3

LS2

RED

M C HI

RO

S4

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LS3

RO

S2

RO

S1

8. S

S1

IS IN

SE

RIE

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ITH

LS

1 A

ND

RO

S3.

T

HE

RM

OS

TA

T.

7. R

EM

OV

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DE

LAY

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ER

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RN

ES

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HE

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GE

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T

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VA

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INE

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T

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L

LS1

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DY

EL

YE

LY

EL

BR

N

GR

D

RO

S4

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HIG

H

LOW

5512

00

2000

BLK

*

BLK

BLK

BLU

BLU

RE

D

RE

D

-

416

00B

LKB

LUR

ED

-

616

00B

LK*

BLK

BLU

RE

D

620

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LK*

BLK

BLU

RE

D

13

BLU

(M

ED

/ME

D H

I)

RED

035-17429-000 REV B (0801)


WIRING DIAGRAM - DOWNFLOW MODELS (P*DD & G8D-DN)NOTE: The furnace’s control system depends on correct polarity of the power supply.

NO

TE

8S

EE

LS1

SS

1R

OS

2

REDN

OT

E 8

SE

E

RE

D

SS

1

WH

TLS

1

RO

S1

BLK

RE

D

RE

D

WH

T

31

RE

DB

LUB

LKB

LK*

2000

6

RE

DB

LUB

LK*

1600

4

RE

DB

LUB

LKB

LK*

1200

5

LOW

HIG

H

LS1

GR

D

YE

L

LS1

YE

L

120

VA

C L

INE

WH

T

WH

T

8. S

S1

IS IN

SE

RIE

S W

ITH

LS

1 A

ND

R0S

1.

TH

ER

MO

ST

AT

.7.

RE

MO

VE

TH

E D

ELA

Y T

IME

R H

AR

NE

SS

WH

EN

US

ING

A 2

ST

AG

E

RO

S1

RO

S2

LS2

RO

S2

HICM

RED

LS2

RO

S1

3A

2ND

ST

AG

E1ST

ST

AG

E

3A

BR

NB

LU

BLK

WH

T

RE

D

BLK

WH

T

RE

D

BR

N

RE

D

BR

N

2

BLK

5

035-

1742

8-00

0A

CE

LLC

FM

CO

OL

HIG

HH

EA

TLO

WH

EA

TP

AR

K

WH

T

CO

OL

PA

RK

HE

AT

LO

1 2 3 4

LIN

E

XF

MR

CIR

CP2/S2

PR

P12 11 10

9 8 7

6 5 4

3 2 1

HE

AT

HI

BR

N

1RC

BR

N

BLO

WE

RM

OT

OR

GRN

MO

TO

RV

EN

TO

RNO

C N.O

.SW

DO

ORPR

I

24V

SE

C

CO

M12

0V

120V

AC

2LP

BLU

SE

NS

OR

FLA

ME

GR

N

GRN

BR

NP

4/S

4

P3/

S3

3 1

21

BLK

WH

T

BLK

WH

T

WH

T

IG

NIT

ER

HO

T S

UR

FA

CE

BLO

WE

R S

PE

ED

FO

R D

ES

IRE

DS

EE

CH

AR

T

P1/

S1

JU

MP

ER

ED

. H

I AN

D C

OO

L T

ER

MIN

ALS

* U

NIT

S S

HIP

PE

D W

ITH

HE

AT

----

- F

IELD

WIR

ING

AN

D D

EV

ICE

SF

AC

TO

RY

WIR

ING

AN

D D

EV

ICE

S

24V

CO

NN

EC

TIO

N R

OO

M T

HE

RM

OS

TA

T

IDE

NT

IFIE

D R

UN

CA

PA

CIT

OR

1T

TR

AN

SF

OR

ME

R, 4

0VA

1RC

RU

N C

AP

AC

ITO

R2L

P P

RE

SS

UR

E S

W, S

EC

ON

D S

TA

GE

1LP

PR

ES

SU

RE

SW

, FIR

ST

ST

AG

E

FU

SE

SE

RV

ICIN

G T

HIS

UN

ITO

PE

N A

LL D

ISC

ON

NE

CT

S B

EF

OR

E

- C

AU

TIO

N -

SS

1 S

PIL

L S

WIT

CH

(C

HIM

NE

Y K

IT)

RO

S2

RO

LL O

UT

SW

ITC

H T

OP

LE

FT

(6

CE

LL O

NLY

)

T

OP

RIG

HT

(6

CE

LL)

RO

S1

RO

LL O

UT

SW

ITC

H T

OP

MID

DLE

(3-

5 C

ELL

) L

S2

AU

XIL

AR

Y L

IMIT

SW

ITC

H O

N B

LOW

ER

LS

1 P

RIM

AR

Y L

IMIT

SW

ITC

HP

5/S

5 3

PIN

PLU

G &

SO

CK

ET

ON

VA

LVE

P4/

S4

3 P

IN P

LUG

& S

OC

KE

T A

T IN

DU

CE

R M

OT

OR

P3/

S3

2 P

IN P

LUG

& S

OC

KE

T A

T H

OT

SU

RF

AC

E IG

NIT

OR

P2/

S2

5 P

IN P

LUG

& S

OC

KE

T O

N IG

N. C

ON

TR

OL

BO

AR

DP

1/S

1 1

2 P

IN P

LUG

& S

OC

KE

T O

N IG

N. C

ON

TR

OL

BO

AR

D I

GN

HO

T S

UR

FA

CE

IGN

ITO

R

GV

GA

S V

ALV

E

DS

DIS

CO

NN

EC

T S

WIT

CH

LEG

EN

D

NO

TE

S:

IGN

MO

TO

RV

EN

TO

R

1T (

40V

A)

PR

I

24V

SE

C

120V

CO

M

NOC

DS

GR

D

SE

E N

OT

E 1

PO

WE

R S

UP

PLY

120

-1-6

0

ELE

ME

NT

AR

Y D

IAG

RA

M

DO

OR

SW

ITC

H N

.O.S

W

GR

D

GV

RE

LAY

IGN

ITE

R

80%

CO

UN

TE

RF

LOW

TW

O-S

TA

GE

FU

RN

AC

E

1RC

HI H

EA

T

CO

OL

MO

TO

RB

LOW

ER

HU

MID

IFIE

R

EA

CE

AC

EA

C

HU

MH

UM

FIE

LD C

ON

NE

CT

ION

(C

) LO

CA

L O

R C

ITY

CO

DE

S.

(B

) C

AN

AD

IAN

ELE

C. C

OD

E (

CE

C)

AN

D/O

R1.

ALL

FIE

LD W

IRIN

G P

ER

: (A

) N

AT

ION

AL

ELE

C. C

OD

E (

NE

C)

AN

D/O

R

H

AV

ING

A T

EM

PE

RA

TU

RE

RA

TIN

G O

F A

T L

EA

ST

221

ßF

(10

5ßC

).

MU

ST

BE

RE

PLA

CE

D, I

T M

US

T B

E R

EP

LAC

ED

WIT

H W

IRIN

G M

AT

ER

IAL

2. IF

AN

Y O

F T

HE

OR

IGIN

AL

WIR

E A

S S

UP

PLI

ED

WIT

H T

HE

FU

RN

AC

E

3. C

ON

NE

CT

OR

S S

UIT

AB

LE F

OR

CO

PP

ER

CO

ND

UC

TO

RS

ON

LY.

4. A

LL R

EP

LAC

EM

EN

T C

OM

PO

NE

NT

S M

US

T B

E P

RO

PE

RLY

GR

OU

ND

ED

.

5. P

RO

VID

E D

ISC

ON

NE

CT

S F

OR

ALL

PO

WE

R S

UP

PLI

ES

.

6. M

OT

OR

S A

RE

INH

ER

EN

TLY

PR

OT

EC

TE

D.

CO

NN

EC

TIO

N D

IAG

RA

MB

LOW

ER

SP

EE

D C

HA

RT

1LP

CNO

NO

2LP

C

LIN

E

GR

D

GR

N

GR

D3

1200

412

00

BLK

BLU

YE

L

BLK

BLU

YE

LR

ED

XF

MR

CO

NT

RO

L B

OA

RD

RE

LAY

CO

NT

AC

TS

ON

IGN

ITIO

N

BLK

WHT

BLU

WH

T

BLK

OR

N

WH

T BLK

BLU

NOC

CAV021TOH

L C

A A

R V

TU 0

E 2

N

1

EA

C

HU

M

WY

RG

B1

W2

TIM

ER

ON

D

ELA

Y

WH

T

BLU

HU

ME

AC

BLK

BLK

LIN

E12

0VA

C.

MA

IN

VA

LVE

2 S

TA

GE

5S\5P

LOW

HE

AT

NOC

1LP

W

OF

F

HE

AT

CO

OL

Y

AU

TO

ON

HE

AT

/CO

OL

TH

ER

MO

ST

AT

R

BR W1

Y

GG W

2

TOD

BLK

(H

I)

YE

L (M

ED

LO

W)

WH

T (

NE

UT

)

RE

D (

LOW

)

BLU

(M

ED

/ME

D H

I)

Subject to change without notice. Printed in U.S.A. 035-17429-000 Rev. B (0801)Copyright © by Unitary Products Group 2000. All rights reserved. Supersedes: 035-17429-000-A-0400

Unitary 5005 NormanProduct York OKGroup Drive 73069

NOTES

installation two-stage gas-fired mid-efficiency … · downflow models p*dd / g8d-dn downflow 1 6 0...

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